DE102017100510A1 - VEHICLE COMPONENT WITH DUMPED ELECTRIC CONDUCTIVE STRUCTURE AND MANUFACTURING METHOD FOR SUCH A - Google Patents

Abstract

The invention relates to a method for producing a vehicle component (1) with an electrical guide structure (3) arranged thereon, at least between a first electrical contact point (4) for feeding in and a second electrical contact point (5) spaced apart for picking up an electrical contact point Stroms extends. According to the invention, the vehicle component (1) is provided. Then, the conductive structure (3) is formed by applying a foamed, electrically conductive metal material to a surface (2) of the vehicle component (1). In such a way that the metal material extends continuously between the at least two electrical contact points (4, 5). Furthermore, the invention also relates to a vehicle component (1) with a foamed electrical guide structure (3).

Description

Technical area

The present invention relates to a method of manufacturing a (power) vehicle component having an electrical conduction structure that can be used to replace an electrical line or a vehicle wiring harness. Further, the invention relates to a vehicle component, such as an interior trim part for a door, a vehicle floor, a vehicle roof or the like, with an electrically conductive structure.

State of the art

For example, from the DE 10 2007 022 764 B3 It is known that in motor vehicles a plurality of electrical lines is laid, which transmit electrical signals and / or working currents between electrical contact points, so for example, signal and / or energy sources with electrical loads or consumers of the vehicle interconnect. The production of vehicle-specific or vehicle equipment-specific electrical lines, which may also be combined into cable sets or a wiring harness, takes place on so-called building rebates and is complicated, since the lines along their longitudinal extent between a start and a destination plug (as an example of an electric Contact point) are hooked into a plurality of line receptacles to combine them into a strand and provided for example with holding parts or other fastening means for attachment to the vehicle.

This process is time-consuming and can currently only be realized manually. The predominantly manual production is particularly due to the necessary movements, such. As the threading of lines, the wrapping and in particular branching of strands, the striking of contacts and end plugs to the lines, the fixing of strands with cable ties and the attachment of holding parts. To date, these movements can only be partially automated, since automation is already made more difficult by the current construction of the construction rescue and the resulting complexity of the movements to be controlled.

The DE 101 21 925 A1 proposes to simplify the manufacture and assembly of electrical wiring or wiring harnesses in motor vehicles to arrange electrical wires on a support, such as a door technology support. In this case, individual wires are laid mechanically on the support and fixed by hot glue. Subsequently, the bare wires can be covered with an electrically insulating protective layer. The disadvantage of this is that, in addition, wires must be laid with a length of the longitudinal length which is in some cases difficult to handle, so that the movements to be controlled in the case of automation continue to be complex.

Description of the invention

An object of the invention is therefore to provide a simple way to connect two contact points in a vehicle using structurally simple means possible.

The object is solved by the subject matters of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

An inventive method for producing a vehicle component provides in principle that no cables, wires or wires are attached to the vehicle component more to connect an electrical connection between two electrical contact points of the vehicle with each other. Instead, an electrical routing structure, e.g. a current path, a type of large cross-sectional trace or the like, is provided, which extends at least between a first electrical contact point for feeding and a spaced second electrical contact point for tapping an electric current. The contact points correspond in principle to the free ends of a conventional line or a cable to which previously electrical contact elements, such as connectors, cable lugs or the like, are attached. They are also arranged according to the invention, electric or electronic components by e.g. Plugging, screwing, soldering, welding, crimping or a similar connection technology.

According to the invention, the vehicle component, which is preferably an interior trim part, such as a door or trunk trim, a door sill trim, a headliner or the like, is provided. It is also possible to provide a guide structure carrier manufactured separately from the vehicle component, which is set up to be subsequently attached to the vehicle component. The vehicle component can, for example, consist of a plastic possibly with fiber components and if necessary have a surface structuring. On or on the vehicle component, the conductive structure is then formed in principle by prototyping by applying or applying a foamed, electrically conductive metal material to a surface, eg surface, of the vehicle component as a foam compound. Metal foams are in the field of materials science known and represent a porous metal material, which may be based on, for example, aluminum, copper, nickel or other electrically conductive metal. The foamed metal material is applied so that it extends continuously between the at least two electrical contact points, so - similar to a conductor or a cable - produces an electrically conductive direct connection between the two contact points. It is possible that the metal material adheres to it alone or by admixed additives or due to the surface structuring of the vehicle component and is held solely by it.

The inventive method brings about several advantages. Thus, by the direct application of the metal material to the vehicle component motion sequences that would be necessary in the production of a wiring set, saved, and thus the wiring harness provision easier to be automated. For example, when using a foam, the wrapping of the leads and the attachment of holding parts for attachment to the vehicle component or anywhere on the vehicle is eliminated. Also, the previous installation in the vehicle by laying the line, contacting or connecting the same with contact points and attaching to the vehicle is simplified, since only the previously required vehicle component and then only the lead structure still has to be electrically coupled. A construction kit also no longer needs to be made available because the lead structure is applied as foam compound directly onto the vehicle component.

An advantageous development of the invention provides that the metal material is applied bead-shaped with a matched to a predetermined current carrying capacity cross-sectional size. Depending on whether an electrical load, such as a power window motor or the like, is to be controlled or supplied with a working current via the conductive structure, or whether only one (smaller absolute) control current is to be conducted, the required current-carrying capacity of the conductive structure can vary be. Here, similar to a conventional line, the cross-sectional size of the lead structure may be adjusted by applying more or less foam mass relative to a length section.

In order to achieve electrical insulation of the actual conductor (internal to cables) as in conventional cables or cables, a foamed, electrically insulating plastic can be applied as an electrical insulation on and / or around the conductive structure at least in sections. This can be done successively by first applying the metal material as a foam compound and then the plastic as a foam mass. But it is also possible that a tool for applying the metal material is adapted to simultaneously a track with the metal material and slightly to the rear offset a shell, apply a coating or the like with the plastic.

The foamed metal material may be a composition or a mixture of a metal powder and a preferably powdered blowing agent. The propellant is preferably a metal hydride, such as titanium hydride. Both ingredients present in powder form are first mixed together and then compacted by sintering or extrusion to form a starting material. The starting material is then heated to a temperature above the melting point of the metal, ie about 1085 ° C for copper or about 660.3 ° C for aluminum. In doing so, the propellant, e.g. Titanium dihydride, gaseous hydrogen free and thus foams up the mixture.

A particularly high cost savings through automated production results when the application is carried out by a computer-controlled, motor-driven foaming device. For example, this can be arranged on a robot arm, which can be driven in particular electrically or hydraulically. This can be controlled by a computer-aided control device, so that the method can be automated or performed by machine.

In order to apply the metal material well, it is advantageous if it is foamed and / or applied with the supply of heat. This can e.g. by the heated metering device, which has, for example, one or more heated nozzles, or the like. The metering device can also be adapted to simultaneously, possibly spatially offset slightly from one another, apply both the metal material and the plastic substantially simultaneously.

The guide structure can be applied to a flat surface of the vehicle component. However, to protect the conductive structure from mechanical damage or to improve the electromagnetic compatibility, it may also be advantageous if the metal material is introduced into a negative contour formed on the vehicle component, such as a depression in the form of a groove, or the like.

The line structure can mainly replace previously used line devices. For this purpose, however, it is advantageous if the lead structure can be contacted, for example, by plugging in order to integrate it into a vehicle electrical system. For this it has proven to be advantageous if a preferably solid provided electrical contact element and is at least partially foamed with the metal material. Ideally, the contact element is arranged on a (free) longitudinal end of the conductive structure, namely at the contact points. It is conceivable that the contact element is held solely by the foaming with the metal material to the vehicle component. However, it can also be additionally fastened, for example by a fastening means which is connected to the vehicle component, or by a holder which is connected to the vehicle component or formed thereon and holds the contact element.

The invention also relates to a vehicle component, such as an interior trim panel, having an electrical lead structure mounted thereon. According to the invention, the conductive structure is applied as foamed, electrically conductive metal material on at least one surface of the vehicle component such that it extends continuously between a first electrical contact point for feeding and a second, spaced electrical contact point for tapping an electric current. The contact points are intended to produce an electrical connection to the vehicle electrical system, an electrical energy or signal source and / or an electrical consumer.

The vehicle component can be prefabricated by first being replaced by e.g. Injection molding or another molding method of e.g. a plastic, possibly with fibers, molded and then provided with the foamed metal material. In order for a delivery of the vehicle component together with the attached lead structure to a vehicle manufacturer is possible, the separate attachment of wiring sets deleted. The assembly in the vehicle is therefore also particularly simple, since only (still) the vehicle component (as before) must be mounted. Moreover, only the lead structure at the pads needs to be replaced by e.g. electrical connectors are contacted. It also eliminates on the supplier side, the production of the wiring harness, which must be made mainly manually due to wrapping with wrapping tapes and the attachment of holding parts for attachment to the vehicle. Here, the invention provides a possibility for improved mechanical or automated production.

For a good current carrying capacity, it is advantageous if the metal material is applied bead-shaped on the surface of the vehicle part.

So far, electrical cables or cables are surrounded by an insulating jacket. In order to electrically insulate the electrical conductive structure, it can be provided that the conductive structure is at least partially surrounded by a foamed, electrically insulating plastic. Advantageously, the application of the plastic by the same or at least a similar method as the application of the metal material for the lead structure, so that this can be done even substantially simultaneously.

For a simple electrical connection to e.g. the vehicle electrical system has proven to be advantageous if at least one of the contact points is formed by a solid electrical contact element which at least partially surrounded by the metal material, so for example. is foamed, is. The contact element may e.g. be designed for a plug-in, screwing or similar connection, so that e.g. a connector plugged and thereby can be connected to the lead structure.

list of figures

• 1 ein erfindungsgemäßes Bauteil, hergestellt nach dem erfindungsgemäßen Verfahren und
• 2 eine weitere Ausführungsvariante des erfindungsgemäßen Verfahrens.

Hereinafter, advantageous embodiments of the invention will be explained with reference to the accompanying drawings. Show it:

• 1 an inventive component, prepared by the method according to the invention and
• 2 a further embodiment of the method according to the invention.

The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently provided with the same reference numerals.

Detailed description

In 1 is a schematic representation of a vehicle component 1 shown, which may be, for example, an interior trim part for example, a vehicle door. In particular, it may be a carrier which is made of a plastic. At or adjacent to the vehicle component 1 is arranged (not shown) electrical functional element, which may be, for example, a power window motor, a vehicle lighting, an adjustment motor for vehicle mirrors or the like. The vehicle component 1 is adapted to be attached to the vehicle. In the prior art, such a functional element has hitherto been controlled or supplied with electric current via one or more electrical lines. For this purpose, the line was integrated into a vehicle (power) electrical system, that is, for example, electrically connected to an energy source.

The vehicle component 1 has an area 2 on, which is exemplified here as a flat surface, but may also have positive and negative contours. The area 2 of the vehicle component 1 has a surface structuring that allows an electrical conductive structure 3 to carry a current carrying capacity for conducting a control or load current. The lead structure 3 Adhesively adheres to the surface 2 and is therefore not further attached in this embodiment. Ie that the vehicle component 1 and the lead structure 3 are adhesively bonded together by adhesion. The lead structure 3 extends in the finished state throughout the area 2 between electrical contact points 4 and 5 of which one is the binding of the lead structure 3 to the vehicle (power) electrical system and the other of the connection to the functional element is used. Both contact points 4 . 5 are designed as solid, for example formed of a sheet material, contact elements. The contact points 4 . 5 Functionally correspond so conventional contact elements, which are attached to free ends of electrical cables. The contact elements are formed, for example, as plug contacts, so that the conductive structure 3 can be connected by simply plugging it to the vehicle electrical system. It is indicated here by dashed lines, that the respective contact point 4 , 5 forming contact element foamed on one side, ie of the metal foam of the guide structure 3 is surrounded.

The lead structure 3 is formed by a foamed metal material based on copper, which is bead-shaped and continuous over the surface 2 extends to simulate a wiring harness with one or more pliable electrical leads, as used in the prior art. The cross-sectional size of the bead is sized according to the current carrying capacity required for the application, and is even dimensioned here to carry a working current.

The metal foam for the lead structure 3 consists essentially of a metal powder, which is exemplified here copper due to its good electrical conductivity, and also a powdered metal hydride, which is here, for example, titanium hydride. These two components are mixed together and compacted by sintering or extrusion to a starting material. The starting material is then heated to a temperature above the melting point of the metal, whereby the metal hydride releases gaseous hydrogen and the mixture foams.

The lead structure 3 is from an electrical insulation 6 surrounded or enveloped, which is indicated here in sections. The insulation 6 is formed by an electrically insulating, foamed plastic, so a polymer foam, on and / or around the conductive structure 3 is applied around. The polymer foam also adheres to the surface 2 of the vehicle component 1 but may also be secured by additional fasteners.

Out 1 is also a method for producing the conductive structure 3 on the surface 2 of the vehicle component 1 out. It can be seen that a computer-aided controlled foaming device 7 is used, which is a first metering nozzle 7.1 and a second metering nozzle 7.2 having. Both dosing nozzles 7.1 . 7.2 are arranged on a (not shown) robot arm and also heated, so that the metal foam easily from the foaming device 7 come out and on the surface 2 can be distributed. The dosing nozzle 7.1 is to set up the metal foam for the lead structure 3 to distribute. About the dosing nozzle 7.2 can be the polymer foam for electrical insulation 6 on the surface 2 to distribute.

In the embodiment according to 1 So first, the vehicle component 1 provided and then by means of the metering 7.1 the foaming device 7 first the metal foam for the lead structure 3 by foaming and controlled guiding of the dosing nozzle 7.1 applied robotic arm. Then by means of the metering nozzle 7.2 , which is guided by the same or another robot arm, the polymer foam for the insulation 6 on the metal foam of the lead structure 3 applied. For this, the robotic arm moves the distance of the lead structure 3 from.

The embodiment according to 2 differs from the in 1 shown embodiment that the metering nozzles 7.1 . 7.2 the foaming device 7 now held on a common support, such as the robot arm. As a result, both dosing nozzles are here 7.1 . 7.2 together, so at the same time, over the area 2 of the vehicle component 1 guided. Ideally, the metering nozzle 7.1 for the metal foam of the conductive structure 3 in the direction of guidance in front of the metering nozzle 7.2 arranged so that first the metal foam and only then the polymer foam for the iso 6 is applied.

After applying the lead structure 3 and possibly the insulation 6 becomes the vehicle component 1 mounted in the vehicle, with the contact points 4 . 5 be connected to the vehicle electrical system.

LIST OF REFERENCE NUMBERS

1

Vehicle component (for example, interior trim part)

2

Surface (e.g., surface)

3

Electric conductive structure (e.g., metal foam)

4

Electrical contact point (e.g., electrical contact element)

5

Electrical contact point (e.g., electrical contact element)

6

Insulation (e.g., insulating foam)

7

frothing

7.1

dispensing nozzle

7.2

dispensing nozzle

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102007022764 B3 [0002]
• DE 10121925 A1 [0004]

Claims (12)

A method for manufacturing a vehicle component (1) having provided thereon electrical lead structure (3) extending at least between a first electrical contact point (4) for feeding and a spaced apart second electrical contact point (5) for tapping an electric current extends, characterized by the steps: - providing the vehicle component (1), - prototyping the conductive structure (3) by applying a foamed, electrically conductive metal material on a surface (2) of the vehicle component (1) such that the metal material is continuous between the at least two electrical Contact points (4, 5) extends. Method according to Claim 1 , characterized in that the metal material is applied bead-shaped with a matched to a predetermined current carrying capacity cross-sectional size. Method according to Claim 1 or 2 , characterized in that on and / or around the guide structure (3) around at least partially a foamed, electrically insulating plastic as electrical insulation (6) is applied. Method according to one of the preceding claims, characterized in that a composition of a metal powder and a metal hydride is used as the blowing agent as the metal material. Method according to one of the preceding claims, characterized in that the application is carried out by a computer-controlled, motor-driven foaming device (7). Method according to Claim 5 , characterized in that the metal material is foamed and / or applied with the supply of heat. Method according to one of the preceding claims, characterized in that the metal material is introduced into a formed on the vehicle component (1) negative contour. Method according to one of the preceding claims, characterized in that a solid electrical contact element is provided and at least partially foamed with the metal material. Vehicle component (1) having an electrical conductive structure (3), characterized in that the conductive structure (3) is applied as a foamed, electrically conductive metal material on at least one surface (2) of the vehicle component (1) such that it is continuous between a first electrical contact point (4) for feeding and a spaced second electrical contact point (5) for tapping an electric current extends. Vehicle component (1) according to Claim 9 , characterized in that the metal material is applied in a bead shape. Vehicle component (1) according to Claim 9 or 10 , characterized in that the guide structure (3) is at least partially surrounded by a foamed, electrically insulating plastic. Vehicle component (1) according to one of Claims 9 to 11 , characterized in that at least one of the contact points (4, 5) is formed by a solid electrical contact element which is at least partially surrounded by the metal material.

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